7 ENGINEERING

SECTION
Installation - Solvent Welding PVC and CPVC Tubes and Fittings

A. Initial Preparation
1. Make sure the solvent cement you are planning to use is
designed for the specific application you are attempting.
2. Know the physical and chemical characteristics and limitations of
the PVC and CPVC tubing materials that you are about to use.
3. Know the reputation of your manufacturer and their products.
4. Know your own qualifications or those of your contractor. The
solvent welding technique of joining PVC and CPVC tube is a
specialized skill just as any other tube fitting technique.
5. Closely supervise the installation and inspect the finished job
before start-up.
6. Contact the manufacturer, supplier, or competent consulting
agency if you have any questions about the application or
installation of PVC and CPVC tube.
7. Take the time and effort to do a professional job. Shortcuts
will only cause you problems and delays in start-up. By far, the
majority of failures in PVC and CPVC systems are the result of
shortcuts and/or improper joining techniques.

B. Selection of Materials
• Cutting Device - Saw or Tube Cutter
• Deburring Tool, Knife, File, or Beveling Machine (2” and above).
• Brush - Pure Bristle
• Rag - Cotton (not synthetic)
• Primer and Cleaner
• Solvent Cement - PVC for PVC Components and CPVC for CPVC
Components. Use proper type and viscosity.
• Containers - Metal or Glass to hold Primer and Cement. Select the
type of PVC or CPVC materials to be used on the basis of their
application with respect to chemical resistance, pressure rating,
temperature characteristics, etc.
• Insertion Tool - helpful for larger diameter tube and fittings (6”
and above).
Cement
The cement should be a bodied cement of approximately 500 to
1600 centipoise viscosity containing 10 ~ 20% (by weight) virgin
PVC material solvated with tetrahydrofuran (THF). Small quantities
of dimethyl formamide (DMF) may be included to act as a retarding
agent to extend curing time. Select the proper cement: Schedule
40 cement should be used for Schedule 40 and SDR tube sizes 2”
diameter or less. For Schedule 40 and SDR over 2” and all sizes
of Schedule 80 tube, Schedule 80 cement is recommended. Never
use all-purpose cements, commercial glues and adhesives or ABS
cement to join PVC or CPVC tube and fittings.
SAFETY PRECAUTION:
Primers and cements are extremely flammable, and must not be
stored or used near heat or open flame.

Applicators
Select a suitable pure bristle type paint brush. Use a proper width
brush or roller to apply the primer and cement (see chart below).
Speedy application of cement is important due to its fast drying
characteristics.

IMPORTANT NOTE:
A dauber type applicator should only be used on tube sizes 2” and
below. For larger diameter tube, a brush or roller must be used.

Primer RECOMMENDED BRUSH*

SIZE FOR PRIMER AND CEMENT APPLICATION
It is recommended that Tetrahydrofuran (THF) be used to prepare
NOMINAL BRUSH NOMINAL BRUSH
the surfaces of tube and fittings for solvent welding. Do not use TUBE SIZE WIDTH TUBE SIZE WIDTH
water, rags, gasoline, or any other substitutes for cleaning PVC or (IPS) (IN.) (IPS) (IN.)
CPVC surfaces. A chemical cleaner such as MEK may be used. 1/2 1/2 3 1 1/2 - 2 1/2
3/4 1 4 2-3
1 1 6 3-5
1 1/4 1 8 4-6
1 1/2 1 - 1 1/2 10 6-8
2 1 - 1 1/2 12 6-8
2 1/2 1 1/2 - 2 14 6-8
16 8+

7.21
 ENGINEERING
7

SECTION
Installation - Solvent Welding PVC and CPVC Tubes and Fittings

C. Making the Joint

1. Cutting
Tube must be squarely cut to allow for the proper interfacing of the
tube end and the fitting socket bottom. This can be accomplished
with a miter box saw or wheel type cutter. Wheel type cutters are not
generally recommended for larger diameters since they tend to flare
the corner of the tube end. If this type of cutter is used, the flare on
the end must be completely removed.

NOTE:
Power saws should be specifically designed to cut plastic tube.

2. Deburring
Use a knife, plastic tube deburring tool, or file to remove burrs from
the end of small diameter tube. Be sure to remove all burrs from
around the inside as well as the outside of the tube. A slight chamfer
STEP 1
(bevel) of about 10°-15° should be added to the end to permit easier
insertion of the tube into the fitting. Failure to chamfer the edge of
the tube may remove cement from the fitting socket, causing the
joint to leak.

For pressure tube systems of 2” and above, the tube must be

end-treated with a 15° chamfer cut to a depth of approx. 3/32”.
Commercial power bevelers are recommended

3/32” (2.5mm) approx.

10-15°

3. Test Dry Fit of the Joint

Tapered fitting sockets are designed so that an interference fit
should occur when the tube is inserted about 1/3 to 2/3 of the way
into the socket. Occasionally, when tube and fitting dimensions are STEP 2
at the tolerance extremes, it will be possible to fully insert dry tube
to the bottom of the fitting socket. When this happens, a sufficient
quantity of cement must be applied to the joint to fill the gap
between the tube and fitting. The gap must be filled to obtain a
strong, leak-free joint.

4. Inspection, Cleaning and Priming

Visually inspect the inside of the tube and fitting sockets and
remove all dirt, grease or moisture with a clean dry rag. If wiping
fails to clean the surfaces, a chemical cleaner must be used. Check
for possible damage such as splits or cracks and replace if necessary.

5. Depth-Of-Entry Mark
Marking the depth of entry is a way to check if the tube has reached
the bottom of the fitting socket in step #7. Measure the fitting socket
depth and mark this distance on the tube O.D. You may want to add
several inches to the distance and make a second mark as the primer
and cement will most likely destroy your first one.

Apply primer to the surface of the tube and fitting socket with a
STEP 4
natural bristle brush (see chart on page 7.21). This process softens
and prepares the PVC or CPVC for the solvent cementing step.
Move quickly without hesitation to the cementing procedure while
surfaces are still wet with primer.

7.22
 7 ENGINEERING

SECTION
Installation - Solvent Welding PVC and CPVC Tubes and Fittings

6. Application of solvent Cement

• Apply the solvent cement evenly and quickly around the outside
of the tube at a width a little greater than the depth of the fitting
socket.
• Apply a light coat of cement evenly around the inside of the
fitting socket. Avoid puddling.
• Apply a second coat of cement to the tube end.

CAUTION:
When cementing bell-end tube be careful not to apply an excessive
amount of cement to the bell socket or spigot end. This will prevent
solvent damage to the tube. For buried tube applications, do not
throw empty primer or cement cans into the trench alongside the
tube.

NOTE:
Cans of cement and primer should be closed at all times when not in STEP 6
use to prevent evaporation of chemicals and hardening of cement.
They are also very flammable and should be kept away from heat
or flame.

7. Joint Assembly
Working quickly, insert the tube into the fitting socket bottom and
give the tube or fitting a 1/4” turn to evenly distribute the cement.
Do not continue to rotate the tube after it has hit the bottom of the
fitting socket. A good joint will have sufficient cement to make a
bead all the way around the outside of the fitting hub. The fitting
will have a tendency to slide back on the tube while the cement
is wet so hold the joint tightly together for about 15 seconds. For
tube sizes 4” and above, greater axial forces are necessary for the
assembly of interference fit joints. Mechanical forcing equipment
may be needed to join the tube and hold the joint until the cement
“sets”. The joint may have to be held together for up to 3 minutes.
Consult your Hydroseal representative for specifics.
STEP 7
NOTE:
Always wait at least 24 hours before pressure testing a tubing system
to allow cemented joints to cure properly. For colder temperatures, it
may be necessary to wait a longer period of time.

8. Cleanup and Joint Movement

Remove all excess cement from around the tube and fitting with
a dry cotton rag. This must be done while the cement is still soft.
The joint should not be disturbed immediately after the cementing
procedure and sufficient time should be allowed for proper curing of
the joint. Exact drying time is difficult to predict because it depends
on variables such as temperature, humidity and cement integrity.
See the chart on page 7.24 for approximate joint movement times
recommended by several tube and solvent cement manufacturers.
For more specific information, you should contact your HYDROSEAL
representative.

STEP 8

7.23
 ENGINEERING
7

SECTION
Installation - Solvent Welding PVC and CPVC Tubes and Fittings

RECOMMENDED JOINT CURING CHART

TEMPERATURE TEST PRESSURES TEST PRESSURES TEST PRESSURES TEST PRESSURES
RANGE DURING FOR TUBE FOR TUBE FOR TUBE FOR TUBE SIZES
CURE PERIOD SIZES 1/2” TO 1 1/4” SIZES 1 1/2” TO 3’’ SIZES 4” TO 8” 10” TO 16”
UP TO ABOVE 180 TO UP TO ABOVE 180 TO UP TO ABOVE 180 TO UP TO
180 PSI 370 PSI 180 PSI 315 PSI 180 PSI 315 PSI 100 PSI
60°F-100°F 1 HR 6 HR 2 HR 12 HR 6 HR 24 HR 24 HR
40°F-60°F 2 HR 12 HR 4 HR 24 HR 12 HR 48 HR 48 HR
40°F 8 HR 48 HR 16 HR 96 HR 48 HR 8 DAYS 8 DAYS

Helpful Hints
1. Work quickly and carefully. 7. Keep primers and cements away from heat, sparks, and flame.
2. Use liberal amounts of fresh cement. 8. Provide good ventilation to reduce fire hazard and to minimize
3. Do not attempt cementing in the rain or in the presence inhalation of solvent vapors.
of moisture. 9. Do not test with compressed air or gas, and bleed all entrapped
4. Do not cement when the temperature is below 40°F or above air from the system before testing hydrostatically.
100°F. 10. Consult your HYDROSEAL representative for specific questions
5. Do not take shortcuts or bypass recommended steps. or problems.
6. Do not weld steel tubing that has been connected to freshly
cemented PVC or CPVC tube.

AVERAGE NUMBER OF JOINTS PER QUART OF CEMENT

TUBE DIAMETER 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 6 8 10 12 14 16

NUMBER OF JOINTS 300 200 125 120 90 60 45 40 30 10 5 2-3 1-2 3/4 1/2

APPLICABLE SPECIFICATIONS FOR SOLVENT WELDING

ASTM D-2564 Solvent cements for PVC plastic pipe and fittings.

ASTM D-2855 Making solvent-cemented joints with PVC pipe and fittings.

ASTM F-493 Solvent cements for CPVC plastic pipe and fittings.

ASTM F-656 Primers for use in solvent cement joints of PVC plastic pipe and fittings.

Hydrostatic Pressure Testing

1. The last assembled joint should be fully cured before filling the
system with water.
2. All valves and air relief mechanisms should be opened at the
ends and elevations. The system should be filled slowly, flow
velocities should not exceed 1 foot per second (Velocity-GPM
charts pages 7.08 ~ 7.11). This will prevent surge, water hammer,
and air entrapment.
3. Water flow should continue until all entrapped air is completely
flushed out of every branch of the system. Maintain the 1 ft/s
velocity until every valve is checked. A rapidly fluctuating gauge
needle during pressure rise may be an indication that entrapped
air still remains in the system.
Systems should include the appropriate air relief and vacuum
breaker valves to vent air during normal operation after
installation. Entrapped air is major cause of surge and burst
failure in plastic tubing systems.
4. After filling the system, do not pressurize until the responsible
engineer is present to witness the test. All personnel in the
vicinity of the system should wear safety glasses and hard hats.
High voltage electrical equipment should be shielded from a
possible spray.
5. The tubing system should be pressurized to 125% of its
maximum design operating pressure. This pressure must not
exceed the working pressure of the lowest rated component in
the system, i.e. flanges, unions, thread parts, valves, etc.
6. The pressure test should not exceed 1 hour. This should provide
enough time to inspect all joints for leaks. If leaks are found,
pressure must be relieved and the leak repaired. The system
should then be recharged and retested. Consult your Hydroseal
representative if you have any questions concerning these steps.
DO NOT USE AIR OR INERT GAS TO TEST,
THIS INCLUDES AIR-OVER-WATER BOOSTERS.

7.24